U.S. patent application number 12/520757 was filed with the patent office on 2010-03-04 for operator interface controllable brake with field responsive material.
This patent application is currently assigned to LORD CORPORATION. Invention is credited to Robert H. Marjoram, Kenneth A. St.Clair.
Application Number | 20100051374 12/520757 |
Document ID | / |
Family ID | 39361782 |
Filed Date | 2010-03-04 |
United States Patent
Application |
20100051374 |
Kind Code |
A1 |
St.Clair; Kenneth A. ; et
al. |
March 4, 2010 |
OPERATOR INTERFACE CONTROLLABLE BRAKE WITH FIELD RESPONSIVE
MATERIAL
Abstract
A vehicle operator input device for controlling the vehicle with
the operator input device including an operator interface lever
moveable by a vehicle operator in first and second directions about
an axis. The operator input device includes a sensor system with a
sensor target. The sensor system senses the moveable operator
interface lever and provides an operator interface lever position
signal as a function of a position of the operator interface lever.
The operator input device includes an interface lever controllable
brake coupled to the operator interface lever, and a brake
controller coupled to the sensor system for receiving the operator
interface mechanism position signal and with the brake controller
coupled to the brake for responsively transmitting a plurality of
brake signals to the brake with the operator interface lever
controllable brake responsively providing resistive braking forces
to the operator interface lever for opposing a force applied to the
operator interface lever by the operator, the operator interface
lever controllable brake providing the resistive braking forces in
response to controller brake signals, with the brake controller
providing a first background force signal followed with a second
below background force drop signal followed with a third above
background stop force signal wherein the operator is provided with
a mechanical detent sensation at a target lever location.
Inventors: |
St.Clair; Kenneth A.; (Cary,
NC) ; Marjoram; Robert H.; (Holly Springs,
NC) |
Correspondence
Address: |
LORD CORPORATION;PATENT & LEGAL SERVICES
111 LORD DRIVE, P.O. Box 8012
CARY
NC
27512-8012
US
|
Assignee: |
LORD CORPORATION
Cary
NC
|
Family ID: |
39361782 |
Appl. No.: |
12/520757 |
Filed: |
December 21, 2007 |
PCT Filed: |
December 21, 2007 |
PCT NO: |
PCT/US2007/088590 |
371 Date: |
June 22, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60871610 |
Dec 22, 2006 |
|
|
|
60893509 |
Mar 7, 2007 |
|
|
|
Current U.S.
Class: |
180/332 ;
303/20 |
Current CPC
Class: |
B60T 7/085 20130101;
F16D 57/002 20130101; B60T 17/22 20130101; B60T 7/042 20130101;
B60T 13/748 20130101 |
Class at
Publication: |
180/332 ;
303/20 |
International
Class: |
B60K 26/00 20060101
B60K026/00; B60T 15/14 20060101 B60T015/14 |
Claims
1. A vehicle, said vehicle including an operator input device for
controlling said vehicle, said operator input device including an
operator interface lever, said operator interface lever moveable by
a vehicle operator in at least a first direction and at least a
second direction about an axis, a sensor system including a sensor
target, said sensor system for sensing said moveable operator
interface lever, said sensor system providing an operator interface
lever position signal as a function of a position of said operator
interface lever, an operator interface lever controllable brake
coupled to said operator interface lever, a brake controller
coupled to the sensor for receiving the operator interface
mechanism position signal and with the brake controller coupled to
the brake for responsively transmitting a plurality of brake
signals to the brake with said operator interface lever
controllable brake responsively providing a plurality of resistive
braking forces to said operator interface lever for opposing a
force applied to the operator interface lever by the operator, said
operator interface lever controllable brake providing said
resistive braking forces in response to a plurality of controller
brake signals, with said brake controller providing a first
background force signal followed with a second below background
force drop signal followed with a third above background stop force
signal wherein said operator is provided with a mechanical detent
sensation at a target lever location.
2. A vehicle as claimed in claim 1, wherein said operator interface
lever controllable brake includes a controllable brake magnetic
field generator, said controllable brake magnetic field generator
generating a controllable magnetic field from a brake controller
electrical current, with said first background force signal
comprised of a background electrical current level, said second
below background force drop signal comprised of a second electrical
current level less than said background electrical current level,
and said third above background stop force signal comprised of a
third electrical current level greater than said background
electrical current level.
3. A vehicle as claimed in claim 1, wherein said second below
background force drop signal is provided when approaching said
target lever location and is not provided when receding from said
target lever location.
4. A controllable brake comprising: a housing comprising a first
chamber and a second chamber, a shaft, the shaft extending through
the first chamber and the second chamber with an axis of rotation,
said shaft having a first shaft end, a controllable brake rotor
made integral with the shaft, said rotor housed in the first
chamber, a controllable brake magnetic field generator located in
the first chamber proximate the controllable brake rotor, said
controllable brake magnetic field generator for generating a
controllable magnetic field strength, and a controllable brake
rotating magnetic target integral with said shaft proximate said
first shaft end, said controllable brake rotating magnetic target
housed in the second chamber, and a controllable brake electronics
circuit board mounted in said second chamber, said controllable
brake electronics circuit board including a first electronic
noncontacting magnetic sensor, said first electronic noncontacting
magnetic sensor monitoring the rotation of said controllable brake
rotating magnetic target and outputting a rotational position of
said controllable brake rotating magnetic target with the
controllable magnetic field strength generated by said controllable
brake magnetic field generator determined by said rotational
position with a first background force controllable magnetic field
strength followed with a second below background force controllable
magnetic field strength followed with a third above background stop
force controllable magnetic field strength providing a detent
sensation at a targeted rotational position.
5. A controllable brake as claimed in claim 4, wherein said
controllable magnetic field strength is provided from a brake
controller electrical current, with said first background force
controllable magnetic field strength provided from a background
electrical current level, said second below background force
controllable magnetic field strength comprised of a second
electrical current level less than said background electrical
current level, and said third above background stop force
controllable magnetic field strength comprised of a third
electrical current level greater than said background electrical
current level.
6. A controllable brake as claimed in claim 4, wherein said second
below background force controllable magnetic field strength is
provided when approaching said targeted rotational position and is
not provided when receding from said targeted rotational
position.
7. A controllable brake as claimed in claim 4, including a lever,
said lever coupled with said shaft.
8. A controllable brake as claimed in claim 4, wherein said brake
provides a plurality of detent sensations at a plurality of
targeted rotational positions.
9. An operator input device, said operator input device including
an operator interface operable by an operator, the operator
interface being moveable in at least first and second directions
along an axis; a position sensor system coupled to the operator
interface for transmitting an operator interface position signal as
a function of the position of the operator interface; a brake
controller system coupled to the position sensor system for
receiving an operator interface position signal and transmitting a
brake signal, and a brake coupled to the brake controller system
and the operator interface for receiving the brake signal and
applying a resistive force to the operator interface, with said
brake controller system providing a first background force signal
followed with a second below background force drop signal followed
with a third above background stop force signal to provide a
mechanical detent sensation at a target operator interface
position.
10. An operator input device, as claimed in claim 9, wherein the
operator interface includes a handle and a rotating shaft coupled
to the handle.
11. An operator input device, as claimed in claim 9, wherein said
detent sensation is provided with respect to a programmable
position of the operator interface.
12. An operator input device, as claimed in claim 9, wherein said
brake controller system provides a first background electrical
current level, a second electrical current level less than said
background electrical current level, and a third electrical current
level greater than said background electrical current level.
13. An operator input device, as claimed in claim 12, wherein said
second electrical current level is less than said background
electrical current level and is provided when approaching said
targeted position and is not provided when receding from said
targeted position.
14. An operator input device, as claimed in claim 9, wherein said
brake controller system provides a plurality of detent sensations
at a plurality of targeted positions.
15. A method of providing a detent sensation, said method of
providing a detent sensation includes providing a first background
force signal, said first background force signal followed with a
second below background force drop signal, and said second below
background force drop signal followed with a third above background
stop force signal to provide a mechanical ball detent mechanism
snap sensation at a targeted location.
16. A method as claimed in claim 15, wherein said first background
force signal, said second below background force drop signal, and
said third above background stop force signal are transmitted to a
controllable magnetic field strength brake as a brake controller
electrical current, with said first background force signal a
background electrical current level, said second below background
force signal a second electrical current level less than said
background electrical current level, and said third above
background stop force signal a third electrical current level
greater than said background electrical current level.
17. A method as claimed in claim 15, wherein said detent sensation
is provided with respect to a programmable position of an operator
interface.
18. A method as claimed in claim 16, wherein said second electrical
current level less than said background electrical current level is
provided when approaching said targeted position and is not
provided when receding from said targeted position.
19. A method of operating a machine, said method of operating a
machine including: providing an operator interface lever, providing
an operator interface lever brake coupled with said operator
interface lever, providing a first background force signal to said
operator interface lever brake, said first background force signal
followed with a below background force drop signal and an above
background stop force signal to provide said operator interface
lever with a mechanical detent sensation at a targeted operation
location of said operator interface lever.
20. A method as claimed in claim 19, wherein said first background
force signal, said below background force drop signal, and said
above background stop force signal are transmitted to said brake as
a brake controller electrical current, with said first background
force signal a background electrical current level, said below
background force signal a second electrical current level less than
said background electrical current level, and said above background
stop force signal a third electrical current level greater than
said background electrical current level.
21. A method as claimed in claim 19, wherein said detent sensation
is provided with respect to a programmable position of said
operator interface lever.
22. A method as claimed in claim 20, wherein said electrical
current level less than said background electrical current level is
provided when approaching said targeted operation location and is
not provided when receding from said targeted location.
23. A method of operating a machine, said method of operating a
machine including: providing an operator interface brake coupled
with an operator positionable interface member, providing a first
background brake force with said operator interface brake, said
first background brake force followed with a second below
background brake force with said operator interface brake, said
second below background brake force less than said first background
brake force, said second below background brake force followed with
a third above background brake force with said operator interface
brake, said third above background brake force greater than said
first background brake force to provide a detent sensation at a
targeted machine operation position of said operator interface
member.
24. A method as claimed in claim 23, wherein said operator
interface brake includes an electromagnetic coil fed with a brake
controlling electrical current, said first background brake force
provided with a first background electrical current level, said
second below background brake force provided with a second
electrical current level less than said background electrical
current level, and said third above background brake force provided
with a third electrical current level greater than said background
electrical current level.
25. A method as claimed in claim 23, wherein said detent sensation
is provided with respect to a programmable position of said
operator interface member.
26. A method as claimed in claim 24, wherein said second electrical
current level less than said background electrical current level is
provided when approaching said targeted machine operation position
and is not provided when receding from said targeted machine
operation position.
27. A computer programmable media containing software to control a
machine operator interface system including: first program
instructions for receiving sensor system position signals, second
program instructions for monitoring said received sensor system
position signals for an approaching targeted detent position
signal, third program instructions for providing brake force
signals related to said received sensor system position signals,
with a first background force output signal, followed with a second
below background force drop output signal followed with a third
above background stop force output signal to provide a detent
sensation at a targeted machine operation detent position.
28. A computer programmable media as claimed in claim 27, said
computer software including receding program instructions wherein a
below background force drop output signal is not outputted when
receding from said targeted machine operation detent position.
29. A computer programmable media as claimed in claim 27, wherein
said sensor system position signals provide a control input into a
machine operation control algorithm.
30. A computer programmable media as claimed in claim 27, including
detent establishment program instructions for establishing a user
programmable position for said targeted machine operation detent
position.
31. A computer programmable media as claimed in claim 27, including
program instructions for providing a plurality of monitored
targeted positions and providing a mechanical detent sensation at
said monitored targeted positions.
32. A computer programmable media as claimed in claim 27, including
angle monitoring program instructions for monitoring an angular
position of a sensor target.
33. A computer programmable media as claimed in claim 27, including
predetermine data program instructions for providing an
electromagnetic current level correlated with a monitored position
of said operator interface system.
34. A computer programmable media as claimed in claim 27, including
monitored position input force generator output program
instructions for providing a force generator controller signal as a
function of a monitored position of said operator interface
system.
35. A computer program product for controlling an operator input
device with an operator interface force generator and a sensor
system for sensing a plurality of positions of an operator
interface member coupled with said operator interface force
generator, said computer program product comprising: a computer
readable medium, first program instructions for monitoring said
positions of said operator interface member, second program
instructions to provide a first background force with said operator
interface force generator, followed with a below background force
with said operator interface force generator, followed with an
above background force with said operator interface force generator
to provide a mechanical ball detent sensation at a monitored
targeted position of said operator interface member.
36. A computer program product as claimed in claim 35, including
reprogrammable position program instructions for establishing a
user programmable position for said monitored targeted
position.
37. A computer program product as claimed in claim 35, including
direction monitoring program instructions for monitoring an
approaching directional movement towards said monitored targeted
position and for monitoring a receding directional movement away
from said monitored targeted position, wherein said below
background force drop signal is provided when approaching said
monitored targeted position and is not provided when receding from
said monitored targeted position.
38. A computer program product as claimed in claim 35, including
program instructions for providing a plurality of monitored
targeted positions and providing a mechanical detent sensation at
said monitored targeted positions.
39. A computer program product as claimed in claim 35, including
angle monitoring program instructions for monitoring an angular
position of a sensor target.
40. A computer program product as claimed in claim 35, including
lookup table program instructions for providing an electromagnetic
current level correlated with a monitored position of said operator
interface member.
41. A computer program product as claimed in claim 35, including
monitored position input force generator output program
instructions for providing a force generator controller signal as a
function of a monitored position of said operator interface
member.
42. A controllable brake comprising an operator input movable
member, said operator input movable member movable by an operator
input motion, said controllable brake including an operator input
sensor system, said operator input sensor system sensing a position
of said operator input movable member, said controllable brake
including an electromagnetic brake member, and said controllable
brake including a means for controlling said electromagnetic brake
member in order to produce a mechanical detent sensation.
43. A machine operation input device, said machine operation input
device including a movable operator interface member and an
electromagnetic operator interface sensor system for sensing a
plurality of operator interface member positions, wherein said
machine operation input device includes a means for providing a
mechanical ball detent sensation when said movable operator
interface member is moved to a targeted operator interface member
position.
44. An operator input device as substantially described herein
and/or substantially shown in the included drawings.
45. A method of making an operator input device as substantially
described herein and/or substantially shown in the included
drawings.
46. A method of operating a machine as substantially described
herein and/or substantially shown in the included drawings.
47. Any invention described or claimed herein.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application Ser. No. 60/893,509, filed Mar. 7, 2007, and to
U.S. Provisional Patent Application Ser. No. 60/871,610, filed Dec.
22, 2006, both of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0002] In an embodiment the invention includes a vehicle with an
operator input for controlling a vehicle operation with an operator
interface lever with a controllable brake. The vehicle operator
input includes a brake controller which provides a mechanical
detent sensation.
[0003] In an embodiment the invention includes a controllable brake
with a brake housing. The brake housing contains a controllable
brake rotor with a shaft. The brake includes a controllable brake
magnetic field generator proximate the controllable brake rotor for
generating a controllable magnetic field strength. The brake
includes a sensor system with a sensor target and a controllable
brake electronics circuit board including a first electromagnetic
noncontacting sensor monitoring the rotation of the controllable
brake rotating sensor target and outputting a rotational position
of the controllable brake rotating target and brake rotor. The
controllable magnetic field strength generated by the controllable
brake magnetic field generator is determined by the rotational
position of the sensor target and the brake rotor to control a
relative motion of the controllable brake rotor preferably with a
first background force controllable magnetic field strength
followed with a second below background force controllable magnetic
field strength followed with a third above background stop force
controllable magnetic field strength providing a mechanical detent
sensation at a targeted rotational position.
[0004] Preferably the rotor brake force generated by the current
fed to the controllable brake magnetic field generator
electromagnetic coil utilizes the monitored position of the sensor
target and the brake rotor to produce a mechanical ball detent feel
at the targeted rotational position with a background base line
force provided with a baseline magnetic field generator floor
current followed with a second below background force dropped down
magnetic field generator below floor near zero current followed
with a third above background stop force controllable magnetic
field strength current greater than the background baseline floor
current.
[0005] In an embodiment the invention includes an operator input
device. The operator input device including an operator interface
operable by an operator, the operator interface being moveable in
at least first and second directions along an axis. The operator
input device including a position sensor system coupled to the
operator interface for transmitting an operator interface position
signal as a function of the position of the operator interface. The
operator input device including a brake controller system coupled
to the position sensor system for receiving an operator interface
position signal and responsively transmitting a brake signal. The
operator input device including a brake coupled to the brake
controller system and the operator interface for receiving the
brake signal and responsively applying a resistive force to the
operator interface. The input device brake controller system
preferably includes program instructions for providing a below
background force drop signal followed with an above background stop
force signal to provide a mechanical ball detent mechanism snap
sensation at a target operator interface position, preferably with
the below background force drop signal preceded with a first
background force signal current floor.
[0006] In an embodiment the invention includes a method of
providing a detent sensation. The method preferably includes
providing a first background force signal. The method preferably
includes providing a second below background force drop signal
followed with a third above background stop force signal to provide
a mechanical ball detent mechanism sensation at a targeted
location.
[0007] In an embodiment the invention includes a method of
operating a machine. The method of operating a machine preferably
includes providing an operator interface lever. The method of
operating a machine preferably includes providing an operator
interface lever brake coupled with the operator interface lever.
The method of operating a machine preferably includes providing a
background force signal to the operator interface lever brake, the
first background force signal followed with a below background
force drop signal and an above background stop force signal to
provide the operator interface lever with a mechanical detent
sensation at a targeted operation location of the operator
interface lever.
[0008] In an embodiment the invention includes a method of
operating a vehicle machine. The method of operating the machine
preferably includes providing an operator interface brake coupled
with an operator positionable interface member. Preferably the
operator positionable interface member is movable to machine
operation positions to operate the machine, preferably with the
member comprising a vehicle lever for controlling a machine
operation. The method preferably includes providing a first
background brake force with the operator interface brake, the first
background brake force followed with a second below background
brake force with the operator interface brake, the second below
background brake force less than the first background brake force,
the second below background brake force followed with a third above
background stop brake force with the operator interface brake, the
third above background brake force greater than the first
background brake force to provide a detent mechanism snap sensation
sensible by an operator moving the interface member at a targeted
machine operation position of the operator interface member.
Preferably the second below background force is a drop in brake
force and a drop in the operator applied force needed to continue
the movement of interface member by operator towards the target,
preferably with the dropped force approaching zero, preferably with
a near zero current brake drag force.
[0009] In an embodiment the invention includes a computer
programmable media containing software to control a machine
operator interface system. Preferably the computer software
includes first program instructions for receiving sensor system
position signals. Preferably the computer software includes second
program instructions for monitoring the received sensor system
position signals for an approaching targeted detent position
signal. The computer software includes third program instructions
for providing brake force signals related to the received sensor
system position signals, preferably with a first background force
output signal, followed with a second below background force drop
output signal followed with a third above background stop force
output signal to provide a detent sensation at a targeted machine
operation detent position.
[0010] In an embodiment the invention includes a computer program
product for controlling an operator input device with an operator
interface force generator and a sensor system for sensing a
plurality of positions of an operator interface member coupled with
the operator interface force generator. Preferably the computer
program product comprises a computer readable medium, first program
instructions for monitoring the positions of the operator interface
member, second program instructions to provide a first background
force with the operator interface force generator, followed with a
below background force with the operator interface force generator,
followed with an above background force with the operator interface
force generator to provide a mechanical ball detent sensation
sensible by an operator moving the interface member at a monitored
targeted position of the operator interface member.
[0011] In an embodiment the invention includes a controllable brake
comprising an operator input movable member, the operator input
movable member movable by an operator input motion. The
controllable brake includes an operator input sensor system, the
operator input sensor system sensing a position of the operator
input movable member. Preferably the controllable brake includes an
electromagnetic brake member. Preferably the controllable brake
includes a means for controlling the electromagnetic brake member
in order to produce a mechanical detent sensation.
[0012] In an embodiment the invention includes a machine operation
input device. Preferably the machine operation input device
includes a movable operator interface member and an electromagnetic
operator interface sensor system for sensing a plurality of
operator interface member positions. Preferably the machine
operation input device includes a means for providing a mechanical
ball detent sensation when the movable operator interface member is
moved to a targeted operator interface member location.
[0013] It is to be understood that both the foregoing general
description and the following detailed description are exemplary of
the invention, and are intended to provide an overview or framework
for understanding the nature and character of the invention as it
is claimed. The accompanying drawings are included to provide a
further understanding of the invention, and are incorporated in and
constitute a part of this specification. The drawings illustrate
various embodiments of the invention and together with the
description serve to explain the principals and operation of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A-B show cross section views of an operator interface
controllable brake device.
[0015] FIG. 2A-B show cross section views of an operator interface
controllable brake device.
[0016] FIG. 2C shows a view of an operator interface controllable
brake with the circuit board illustrated transparently to show
electronic noncontacting magnetic sensors oriented on both sides of
the circuit board.
[0017] FIG. 3 shows an operator interface controllable brake system
schematic.
[0018] FIG. 4 shows four positional outputs for an operator
interface controllable brake with two oriented electronic
noncontacting magnetic sensors.
[0019] FIG. 6A-B illustrates a marine vehicle machine with an
operator interface controllable brake device lever with multiple
detent positions for controlling the operation of the vehicle.
[0020] FIG. 7 shows a lever brake profile with multiple (3) detent
sensation clicks with 180 degree rotation of interface lever
rotating about the brake shaft axis with position plotted along the
x-axis and current along the y-axis with the current floor
background force between the force drop and the maximum brake force
currents for the particular detent.
[0021] FIG. 8 shows a lever brake profile for a detent sensation
click targeted interface lever position centered about position
3000 with the lever rotating about the brake shaft axis with
position plotted along the x-axis and current along the y-axis with
the current floor background force between the force drop and the
maximum brake force current.
[0022] FIG. 9 shows plots of angle position (such as sensed by the
position sensor) in the x-axis direction compared with current to
the brake EM coil to produce brake force torque in the y-axis
direction with the top half illustrating clockwise rotation of the
brake rotor and the bottom half illustrating counterclock wise
rotation of the brake rotor, with w (position width of above and
below force current) greater than the resolution of the position
sensor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Additional features and advantages of the invention will be
set forth in the detailed description which follows, and in part
will be readily apparent to those skilled in the art from that
description or recognized by practicing the invention as described
herein, including the detailed description which follows, the
claims, as well as the appended drawings.
[0024] Reference will now be made in detail to the present
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0025] In an embodiment the invention includes a vehicle. The
vehicle preferably includes an operator input device for
controlling the vehicle, the operator input device including an
operator interface mechanism for a vehicle operation function.
Preferably the operator interface mechanism is operable by an
operator, preferably with the operator interface mechanism
comprising a lever. Preferably the operator interface lever is
moveable by a vehicle operator in at least a first direction and at
least a second direction about an axis. Preferably the operator
input device includes a sensor system including a sensor target,
the sensor system for sensing the moveable operator interface
lever. Preferably the sensor system includes an electronic
noncontacting magnetic sensor, preferably two electromagnetic
sensors opposingly mounted on the two sides of a sensor system
circuit board. Preferably the sensor system target comprises a
controllable brake rotating magnetic sensor target, with the target
coupled to the operator interface mechanism lever for sensing the
moveable operator interface lever. The sensor system outputs and
transmits an operator interface lever position signal as a function
of a position of the operator interface lever. Preferably an
operator interface lever controllable brake is coupled to the
operator interface lever. Preferably a brake controller is coupled
to the sensor for receiving the operator interface mechanism
position signal, with the brake controller coupled to the brake for
responsively transmitting a plurality of brake signals to the brake
with the operator interface lever controllable brake responsively
providing a plurality of resistive braking forces to the operator
interface lever for opposing a force applied to the operator
interface lever by the operator, the operator interface lever
controllable brake providing the resistive braking forces in
response to a plurality of controller brake signals. Preferably,
the brake controller provides a first background force signal floor
current followed with a second below background force drop signal,
followed with a third above background stop force signal wherein
the operator is provided with a mechanical detent sensation at a
target lever location. Preferably the second below background force
drop signal comprises a current drop below the floor current,
preferably to a near zero current level centered about zero.
Preferably the third above background stop force signal comprises a
high current level above the floor current which provides a
substantial resistance to the lever motion after the force drop
below the background force. Preferably the operator interface lever
controllable brake includes a controllable brake magnetic field
generator electromagnet. The controllable brake magnetic field
generator generating a controllable magnetic field from a brake
controller electrical current, with the first background force
signal comprised a background EM coil electrical current level, the
second below background force drop signal comprised of a second EM
coil electrical current level less than the background electrical
current level, and the third above background stop force signal
comprised of a third EM coil electrical current level greater than
the background electrical current level. Preferably the second
below background force drop signal is provided when approaching the
target lever location and is not provided when receding from the
target lever location.
[0026] In an embodiment the invention includes a controllable brake
with a housing comprising a first chamber and a second chamber, a
shaft, the shaft extending through the first chamber and the second
chamber with an axis of rotation, the shaft having a first shaft
end, a controllable brake rotor made integral with the shaft, the
rotor housed in the first chamber. The brake preferably includes a
controllable brake magnetic field generator located in the first
chamber proximate the controllable brake rotor, the controllable
brake magnetic field generator for generating a controllable
magnetic field strength, and a controllable brake rotating magnetic
target integral with the shaft proximate the first shaft end, the
controllable brake rotating magnetic target housed in the second
chamber, and a controllable brake electronics circuit board mounted
in the second chamber, the controllable brake electronics circuit
board having a control board plane, the control board plane
oriented normal to the axis of rotation and including a first
electronic noncontacting magnetic sensor having a first sensor
plane, the first electronic noncontacting magnetic sensor
integrated on the controllable brake electronics circuit board with
the first sensor plane parallel with the control board plane, a
second electronic noncontacting magnetic sensor having a second
sensor plane, the second electronic noncontacting magnetic sensor
integrated on the controllable brake electronics circuit board with
the second sensor plane parallel with the control board plane with
the control board plane between the first sensor plane and the
second sensor plane. Preferably the first electromagnetic
noncontacting sensor, and preferably the second electronic
noncontacting magnetic sensor, monitoring the rotation of the
controllable brake rotating magnetic target and outputting a
rotational position of the controllable brake rotating magnetic
target with the controllable magnetic field strength generated by
the controllable brake magnetic field generator determined by the
rotational position to control a relative motion of the
controllable brake rotor. Preferably brake is controlled with a
first background force controllable magnetic field strength,
preferably a base line force provided with a baseline magnetic
field generator current signal, preferably with a floor current,
followed with a second below background force controllable magnetic
field strength, preferably a dropped down magnetic field generator
current signal with force and a magnetic field less than the
background. Preferably the second below background force current is
approaching zero, prefer about zero, preferably a basement zero
current level below the current floor. Preferably the second below
background force is followed with a third above background stop
force controllable magnetic field strength, preferably with a
magnetic field generator current signal with a maximum force and
magnetic field greater than the background baseline floor current,
providing a mechanical ball detent mechanism snap sensation at a
targeted rotational position. Preferably the controllable magnetic
field strength is provided from a brake controller electrical
current, with the first background force controllable magnetic
field strength provided from a background EM coil electrical
current level, the second below background force controllable
magnetic field strength includes of a second EM coil electrical
current level less than the background electrical current level,
and the third above background stop force controllable magnetic
field strength includes a third EM coil electrical current level
greater than the background electrical current level. Preferably
the second below background force controllable magnetic field
strength is provided when approaching the targeted rotational
position and is not provided when receding from the targeted
rotational position. Preferably the controllable brake includes a
lever, with the lever coupled with the brake rotor shaft,
preferably with the lever comprised of a vehicle operation lever.
In a preferred embodiment the controllable brake vehicle operation
lever is a throttle lever. In a preferred embodiment the
controllable brake vehicle operation lever is a gear shift lever.
Preferably the brake provides a plurality of mechanical ball detent
mechanism snap sensations at a plurality of targeted rotational
positions, preferably spaced out rotational positions, preferably
programmable positions which can be predetermined positions that
can be reprogrammed to new programmed positions.
[0027] In an embodiment the invention includes an operator input
device, the operator input device including an operator interface
operable by an operator, the operator interface being moveable in
at least first and second directions along an axis. The operator
input device includes a position sensor system coupled to the
operator interface for transmitting an operator interface position
signal as a function of the position of the operator interface. The
operator input device includes a brake controller system coupled to
the position sensor system for receiving an operator interface
position signal and responsively transmitting a brake signal. The
operator input device includes a brake coupled to the brake
controller system and the operator interface for receiving the
brake signal and responsively applying a resistive brake force to
the operator interface, with the brake controller system providing
a first background force signal followed with a second below
background force drop signal followed with a third above background
stop force signal to provide a mechanical ball detent mechanism
snap sensation at a target operator interface position. Preferably
the operator interface includes a handle 100 and a rotating shaft
coupled to the handle 100, preferably a vehicle operation lever. In
a preferred embodiment the vehicle operation lever is a throttle
lever. In a preferred embodiment the vehicle operation lever is a
gear shift lever. Preferably the detent sensation is provided with
respect to a programmable position of the operator interface.
Preferably the brake controller system provides a first background
EM coil electrical current level, a second EM coil electrical
current level less than the background electrical current level,
and a third EM coil electrical current level greater than the
background electrical current level. Preferably the second EM coil
electrical current level is less than the background electrical
current level and is provided when approaching the targeted
position and is not provided when receding from the targeted
position. Preferably the brake controller system provides a
plurality of mechanical ball detent mechanism snap sensations at a
plurality of targeted positions, preferably spaced out rotational
positions, preferably programmable positions.
[0028] In an embodiment the invention includes a method of
providing a detent sensation. Preferably the method of providing a
detent sensation includes providing a first background force signal
followed with a second below background force drop signal, and the
second below background force drop signal followed with a third
above background stop force signal to provide a mechanical ball
detent mechanism snap sensation at a targeted location. Preferably
the first background force signal, the second below background
force drop signal, and the third above background stop force signal
are transmitted to a controllable magnetic field strength brake as
a brake controller electrical current, with the first background
force signal a background EM coil electrical current level, the
second below background force signal a second EM coil electrical
current level less than the background electrical current level,
and the third above background stop force signal a third EM coil
electrical current level greater than the background electrical
current level. Preferably the detent sensation is provided with
respect to a programmable position of an operator interface.
Preferably the second EM coil electrical current level less than
the background electrical current level is provided when
approaching the targeted position and is not provided when receding
from the targeted position.
[0029] In an embodiment the invention includes a method of
operating a vehicle machine. Preferably the method of operating a
machine includes providing an operator interface lever, providing
an operator interface lever brake coupled with the operator
interface lever, providing a first background force signal to the
operator interface lever brake, the first background force signal
followed with a second below background force drop signal and a
third above background stop force signal to provide the operator
interface lever with a mechanical ball detent mechanism snap
sensation at a targeted operation location of the operator
interface lever. Preferably the first background force signal, the
second below background force drop signal, and the third above
background stop force signal are transmitted to the brake as a
brake controller electrical current, with the first background
force signal a background EM coil electrical current level, the
second below background force signal a second EM coil electrical
current level less than the background electrical current level,
and the third above background stop force signal a third EM coil
electrical current level greater than the background electrical
current level.
[0030] Preferably the detent sensation is provided with respect to
a programmable position of the operator interface lever. Preferably
the second EM coil electrical current level less than the
background electrical current level is provided when approaching
the targeted operation location and is not provided when receding
from the targeted location.
[0031] In an embodiment the invention includes a method of
operating a vehicle machine. Preferably the method of operating a
machine includes providing an operator interface brake coupled with
an operator positionable interface member, preferably with the
member movable to machine operation positions to operate the
machine, preferably a vehicle lever for controlling a machine
function. Preferably the method includes providing a first
background brake force with the operator interface brake, the first
background brake force followed with a second below background
brake force. Preferably the below background brake force is a drop
in force needed to continue movement of interface member by
operator, preferably approaching zero, preferably with zero as the
no current brake drag force. The second below background brake
force is less than the first background brake force, the second
below background brake force followed with a third above background
stop brake force with the operator interface brake. The third above
background stop brake force is greater than the first background
brake force. The intervening below background brake force
preferably provides a mechanical ball detent mechanism snap
sensation sensible by an operator moving the interface member at a
targeted machine operation position of the operator interface
member. Preferably the operator interface brake includes an
electromagnetic coil fed with a brake controlling electrical
current, the first background brake force provided with a first
background EM coil electrical current level, the second below
background brake force provided with a second EM coil electrical
current level less than the background electrical current level,
and the third above background stop brake force provided with a
third EM coil electrical current level greater than the background
electrical current level. Preferably the detent sensation is
provided with respect to a programmable position of the operator
interface member. Preferably the second EM coil electrical current
level less than the background electrical current level is provided
when approaching the targeted machine operation position and is not
provided when receding from the targeted machine operation
position.
[0032] In an embodiment the invention includes a computer
programmable media containing programmable software to control a
machine operator interface system. Preferably the computer
programmable software includes first program instructions for
receiving sensor system position signals. Preferably the computer
programmable software includes second program instructions for
monitoring the received sensor system position signals for an
approaching targeted detent position signal. Preferably the
computer programmable software includes third program instructions
for providing brake force signals related to the received sensor
system position signals, with preferably a first background force
output signal, followed with a second below background force drop
output signal followed with a third above background stop force
output signal to provide a mechanical detent sensation at a
targeted machine operation detent position. Preferably the computer
software includes receding program instructions wherein a below
background force drop output signal is not outputted when receding
from the targeted machine operation detent position. Preferably the
computer software utilizes sensor system position signals to
provide a control input into a machine operation control algorithm,
preferably with sensor position signals used in addition to a
detent location input also used to operate the machine, such as
position controlling a vehicle throttle an/or vehicle power
transmission.
[0033] Preferably the computer software programmable media includes
detent establishment program instructions for establishing a user
programmable position for the targeted machine operation detent
position. Preferably the computer software programmable media
includes program instructions for providing a plurality of
monitored targeted machine operation positions and providing a
mechanical ball detent mechanism snap sensation at the monitored
targeted machine operation positions. Preferably the computer
software programmable media includes angle monitoring program
instructions for monitoring an angular position of a sensor target.
Preferably the computer software programmable media includes
predetermined data look up table program instructions for providing
an electromagnetic current level correlated with a monitored
position of the operator interface system. Preferably the computer
software programmable media includes monitored position input force
generator output program instructions for providing a force
generator brake controller signal as a function of a monitored
position of the operator interface system.
[0034] In an embodiment the invention includes a computer program
product for controlling an operator input device with an operator
interface brake force generator and a sensor system for sensing a
plurality of positions of an operator interface member coupled with
the operator interface brake force generator. The computer program
product includes a computer readable medium, first program
instructions for monitoring the positions of the operator interface
member, second program instructions to provide a first background
brake force with the operator interface brake force generator,
followed with a second below background brake force, preferably a
drop in force needed to continue movement of the interface member
by the operator, preferably approaching zero, preferably with zero
as the no current brake drag force with the second below background
brake force less than the first background brake force, followed
with a third above background stop brake force with the operator
interface brake force generator, with the third above background
stop brake force preferably greater than the first background brake
force to provide a mechanical ball detent mechanism snap sensation
sensible by an operator moving the interface member at a monitored
targeted machine operation position of the operator interface
member. Preferably the computer program product includes program
instructions for establishing a user programmable position for the
monitored targeted machine operation position. Preferably the
computer program product includes direction monitoring program
instructions for monitoring an approaching directional movement
towards the monitored targeted machine operation position and for
monitoring a receding directional movement away from the monitored
targeted machine operation position, wherein the second below
background force drop signal is provided when approaching the
monitored targeted machine operation position and is not provided
when receding from the monitored targeted machine operation
position. Preferably the computer program product includes program
instructions for providing a plurality of monitored targeted
machine operation positions and providing a mechanical detent
mechanism snap sensation at the monitored targeted machine
operation positions. Preferably the computer program product
includes angle monitoring program instructions for monitoring an
angular position of a sensor target. Preferably the computer
program product includes look up table program instructions for
providing an electromagnetic current level correlated with a
monitored position of the operator interface member. Preferably the
computer program product includes monitored position input force
generator output program instructions for providing a force
generator controller brake signal as a function of a monitored
position of the operator interface member.
[0035] In an embodiment the invention includes a controllable brake
comprising an operator input movable member, the operator input
movable member movable by an operator input motion, the
controllable brake including an operator input sensor system, the
operator input sensor system sensing a position of the operator
input movable member, the controllable brake including an
electromagnetic brake member, and the controllable brake including
a means for controlling the electromagnetic brake member in order
to produce a mechanical detent sensation.
[0036] In an embodiment the invention includes a machine operation
input device, the machine operation input device including a
movable operator interface member and an electromagnetic operator
interface sensor system for sensing a plurality of operator
interface member positions, wherein the machine operation input
device includes a means for providing a mechanical ball detent
sensation when the movable operator interface member is moved to a
targeted operator interface member position.
[0037] In an embodiment the invention provides the feel of a
mechanical ball detent by causing the braking torque to reduce to
near zero for a short detent force drop distance preceding the
desired stop point, where current rises to a relatively high stop
force level. The near zero torque dropout is preferably direction
sensitive. Preferably the zero torque dropout is produced only as
the operator interface lever approaches the detent stop point
target, and preferably not as the operator interface lever leaves
the detent stop point target.
[0038] In an embodiment the detent sensation is provided with a
controllable brake which cannot add energy to the system. In
preferred embodiments the detent sensation is provided with the
controllable brake in a control-by-wire vehicle machine systems for
vehicle operations such as braking, throttle, and shifting while
giving the mechanical detent sensation to the operator by using
such simulated mechanical ball detent force feedback, with a snap
such felt by an operator with an actual mechanical ball detent
mechanism. In a preferred embodiment the detent sensation is
provided with the controllable brake in a control-by-wire marine
vehicle machine system for operating a marine vehicle, preferably
with the operator interface lever controlling the direction
(forward/reverse) and speed (throttle) of a marine vehicle
motor.
[0039] In an embodiment a non-zero current floor is utilized over
the majority of the lever positionable range to provide a
background force. Then, as the lever approaches the target, current
is dropped towards zero (preferably near zero current centered
about zero) with the lever allowed to momentarily accelerate
towards the target. Then the current is increased to a high current
level at the target location, preferably with the high current
level at the target location greater than the non-zero current
floor. The near-zero force preceding a high force combination
preferably provides a mechanical ball detent sensation feel of a
snap going into the detent position. Preferably the near zero
current is used only on approach to the target point, and not when
leaving the target point. The FIG. multiple detent sensations with
180 degree rotation of interface lever rotating about brake shaft
axis provides a data chart for a look-up-table program instruction
approach that is used in an embodiment, with the solid blue line
for increasing lever angle and the dashed red line is for
decreasing lever angle to provide mechanical ball detent sensations
at the three programmed target positions of 3000, 4000, and 5000.
In addition to program instructions with a look-up-table, detent
sensations are providable with code function program instruction
that when approaching the target position generate the detent
commands of brake control signals for the background force followed
by the below background force drop followed with the greater than
background stop force. In an embodiment the code function provides
a greater than zero ramped up floor current preceding the near zero
current force dropout and the high current greater than background
stop force to give the snap.
[0040] The controllable brakes preferably include a housing
including a first chamber and a second chamber. The controllable
brake preferably includes a shaft, the shaft extending through the
first chamber and the second chamber with an axis of rotation, the
shaft having a first shaft end. The controllable brake preferably
includes a controllable brake rotor made integral with the shaft,
the rotor housed in the first chamber. The controllable brake
preferably includes a controllable brake magnetic field generator
located in the first chamber proximate the controllable brake
rotor, the controllable brake magnetic field generator for
generating a controllable magnetic field strength. The controllable
brake preferably includes a controllable brake rotating magnetic
target integrated with the shaft proximate the first shaft end, the
controllable brake rotating magnetic target housed in the second
chamber. The controllable brake preferably includes a controllable
brake electronics circuit board mounted in the second chamber, the
controllable brake electronics circuit board having a control board
plane, the control board plane oriented normal to the shaft axis of
rotation. The controllable brake preferably includes a first
electronic noncontacting magnetic sensor having a first sensor
plane, the first electronic noncontacting magnetic sensor
integrated on the controllable brake electronics circuit board with
the first sensor plane parallel with the control board plane. The
controllable brake preferably includes a second electronic
noncontacting magnetic sensor having a second sensor plane, the
second electronic noncontacting magnetic sensor integrated on the
controllable brake electronics circuit board with the second sensor
plane parallel with the control board plane with the control board
plane between the first sensor plane and the second sensor plane,
the first electronic noncontacting magnetic sensor and the second
electronic noncontacting magnetic sensor monitoring the rotation of
the controllable brake rotating magnetic target and outputting a
rotational position of the controllable brake rotating magnetic
target wherein the controllable magnetic field strength generated
by the controllable brake magnetic field generator is determined by
the rotational position to control a relative motion of the
controllable brake rotor.
[0041] The controllable brakes preferably include a rotating
magnetic target. The controllable brake preferably includes a
magnetically permeable rotor. The controllable brake preferably
includes a shaft connected to the magnetically permeable rotor. The
controllable brake preferably includes a housing having a first
housing chamber rotatably housing the magnetically permeable rotor
therein, and including a magnetic field generator spaced from the
magnetically permeable rotor, and configured and positioned for
generating a controllable magnetic field to control a relative
motion of the magnetically permeable rotor, and a second housing
chamber containing control electronics therein, the second housing
chamber electronics including at least a first oriented electronic
noncontacting magnetic sensor, the at least first oriented
electronic noncontacting magnetic sensor oriented relative to the
rotating magnetic target and the shaft wherein the at least first
oriented electronic noncontacting magnetic sensor monitors the
rotation of the rotating magnetic target.
[0042] The methods preferably include providing a housing having a
first housing chamber and a second housing chamber. The method
preferably includes providing a shaft with a magnetically permeable
rotor, the shaft including a rotating magnetic target distal from
the magnetically permeable rotor. The method preferably includes
providing a magnetic field generator for generating a magnetic
field with a controllable field strength for controlling a relative
motion of the magnetically permeable rotor. The method preferably
includes providing at least a first electronic noncontacting
magnetic sensor, the at least first electronic noncontacting
magnetic sensor integrated on an operation electronic control board
having a control board plane. The method preferably includes
disposing the magnetically permeable rotor and the magnetic field
generator in the first housing chamber. The method preferably
includes disposing the rotating magnetic target and the at least a
first electronic noncontacting magnetic sensor in the second
housing chamber, wherein the operation electronic control board is
in electrical communication with the magnetic field generator and
the control board plane is oriented relative to the rotating
magnetic target, wherein the at least first electronic
noncontacting magnetic sensor provides a detected measured
rotational position of the rotating magnetic target with the
controllable field strength generated in relationship to the
detected measured rotational position sensed by the at least first
electronic noncontacting magnetic sensor.
[0043] The methods preferably include providing a magnetic field
generator for generating a magnetic field with a controllable field
strength for controlling a relative motion of a movable brake
member. The method preferably includes providing a magnetic target
which moves with the relative motion of the movable brake member.
The method preferably includes providing an electronic circuit
board having a circuit board plane, a first oriented electronic
noncontacting magnetic sensor having a first oriented sensor plane,
the first electronic noncontacting magnetic sensor integrated on
the electronic circuit board with the first sensor plane parallel
with the circuit board plane, a second oriented electronic
noncontacting magnetic sensor having a second oriented sensor
plane, the second electronic noncontacting magnetic sensor
integrated on the electronic circuit board with the second sensor
plane parallel with the circuit board plane with the circuit board
plane between the second sensor plane and the first sensor plane.
The method preferably includes disposing the electronic circuit
board proximate the magnetic target wherein the first electronic
noncontacting magnetic sensor and the second electronic
noncontacting magnetic sensor provide a detected measured magnetic
target position with the controllable field strength generated by
the magnetic field generator determined by the detected measured
magnetic target position.
[0044] The methods preferably include providing a control system
rotating magnetic target having an axis of rotation. The method
preferably includes providing a control system electronic circuit
board having a circuit board plane and a first circuit board side
and an opposite second circuit board side, a first oriented
electronic noncontacting magnetic sensor integrated on the
electronic circuit board first circuit board side, a second
oriented electronic noncontacting magnetic sensor integrated on the
electronic circuit board second circuit board side. The method
preferably includes disposing the control system electronic circuit
board proximate the control system rotating magnetic target with a
projected extension of the axis of rotation extending through the
first oriented electronic noncontacting magnetic sensor and the
second oriented electronic noncontacting magnetic sensor wherein
the first electronic noncontacting magnetic sensor and the second
electronic noncontacting magnetic sensor provide a plurality of
detected measured magnetic target rotary position outputs.
[0045] The methods preferably include providing a magnetic field
generator for generating a magnetic field with a controllable field
strength. The method preferably includes providing a field
responsive controllable material, the field responsive controllable
material affected by the magnetic field generator magnetic field.
The method preferably includes providing a magnetic target. The
method preferably includes providing at least a first electronic
noncontacting magnetic sensor, the at least first electronic
noncontacting magnetic sensor integrated on an operation electronic
control board having a control board plane, the operation
electronic control board in electrical communication with the
magnetic field generator and the control board plane oriented
relative to the magnetic target, wherein the at least a first
electronic noncontacting magnetic sensor provides a detected
measured position of the magnetic target with the controllable
field strength generated in relationship to the detected measured
position sensed by the at least first electronic noncontacting
magnetic sensor.
[0046] Preferably the controllable brake includes a housing
comprising a rotor chamber and a sensor chamber, a shaft, the shaft
extending through the rotor chamber and the sensor chamber with an
axis of rotation, the shaft having a shaft end, a controllable
brake rotor made integral with the shaft, the rotor housed in the
rotor chamber, the rotor having a rotation plane, a controllable
brake magnetic field generator located in the rotor chamber
proximate the controllable brake rotor, the controllable brake
magnetic field generator for generating a controllable magnetic
field strength, and a controllable brake rotating magnetic target
proximate the shaft end, the controllable brake rotating magnetic
target housed in the sensor chamber, and a controllable brake first
electronic noncontacting magnetic sensor having a first sensor
plane, the first electronic noncontacting magnetic sensor mounted
in the sensor chamber with the first sensor plane parallel with the
controllable brake rotor rotation plane, the first electronic
noncontacting magnetic sensor monitoring the rotation of the
controllable brake rotating magnetic target and the controllable
brake rotor and simultaneously outputting at least two rotational
positions of the controllable brake rotor wherein the controllable
magnetic field strength generated by the controllable brake
magnetic field generator is determined with the rotational
positions to control a relative motion of the controllable brake
rotor.
[0047] Preferably the electronic noncontacting electromagnetic
sensor preferably comprises an integrated circuit semiconductor
sensor chip with at least two positional outputs. Preferably the
electronic noncontacting magnetic sensor integrated circuit
semiconductor sensor chip has at least two dies. Preferably the at
least two dies are ASICs (Application Specific Integrated
Circuits). In a preferred embodiment the at least two dies are side
by side dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the at least two dies are vertically
stacked dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the integrated circuit semiconductor
sensor chip ASIC die include a magnetoresistive material,
preferably with electrical resistance changes in the presence of
the magnetic target magnetic field, preferably with
magnetoresistive elements arranged in a Wheatstone bridge. In a
preferred embodiment the integrated circuit semiconductor sensor
chip ASIC die include a Hall Effect element, preferably a plurality
of oriented Hall Effect elements, preferably silicon semiconductor
Hall effect elements which detect the magnetic target magnetic
field.
[0048] The controllable brake preferably includes a housing
including a first chamber and a second chamber. The controllable
brake preferably includes a shaft, the shaft extending through the
first chamber and the second chamber with an axis of rotation, the
shaft having a first shaft end. The controllable brake preferably
includes a controllable brake rotor made integral with the shaft,
the rotor housed in the first chamber, with the rotor having a
rotation plane preferably normal to the axis of rotation. The
controllable brake preferably includes a controllable brake
magnetic field generator located in the first chamber proximate the
controllable brake rotor, the controllable brake magnetic field
generator for generating a controllable magnetic field strength.
The controllable brake preferably includes a controllable brake
rotating magnetic target integrated with the shaft proximate the
first shaft end, the controllable brake rotating magnetic target
housed in the second chamber. The controllable brake preferably
includes a controllable brake electronics circuit board mounted in
the second chamber, the controllable brake electronics circuit
board having a control board plane, the control board plane
oriented normal to the shaft axis of rotation. The controllable
brake preferably includes a first electronic noncontacting magnetic
sensor having a first sensor plane, the first electronic
noncontacting magnetic sensor integrated on the controllable brake
electronics circuit board with the first sensor plane parallel with
the control board plane. The controllable brake preferably includes
a second electronic noncontacting magnetic sensor having a second
sensor plane, the second electronic noncontacting magnetic sensor
integrated on the controllable brake electronics circuit board with
the second sensor plane parallel with the control board plane with
the control board plane between the first sensor plane and the
second sensor plane, the first electronic noncontacting magnetic
sensor and the second electronic noncontacting magnetic sensor
monitoring the rotation of the controllable brake rotating magnetic
target and outputting a rotational position of the controllable
brake rotating magnetic target wherein the controllable magnetic
field strength generated by the controllable brake magnetic field
generator is determined by the rotational position to control a
relative motion of the controllable brake rotor.
[0049] In preferred embodiments the electronic noncontacting
magnetic sensors preferably comprise integrated circuit
semiconductor sensor chips with at least two positional outputs.
Preferably the electronic noncontacting magnetic sensor integrated
circuit semiconductor sensor chip has at least two dies. Preferably
the at least two dies are ASICs (Application Specific Integrated
Circuits). In a preferred embodiment the at least two dies are side
by side dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the at least two dies are vertically
stacked dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the integrated circuit semiconductor
sensor chip ASIC die include a magnetoresistive material,
preferably with electrical resistance changes in the presence of
the magnetic target magnetic field, preferably with
magnetoresistive elements arranged in a Wheatstone bridge. In a
preferred embodiment the integrated circuit semiconductor sensor
chip ASIC die include a Hall Effect element, preferably a plurality
of oriented Hall Effect elements, preferably silicon semiconductor
Hall effect elements which detect the magnetic target magnetic
field.
[0050] The controllable brake 500 preferably includes a housing
502. The housing 502 preferably includes a first sealed chamber 504
and a second sealed chamber 506. The controllable brake preferably
includes a shaft 512 with an axis of rotation 516 and a first shaft
end 514. Preferably the shaft extends through the first sealed
chamber and the second sealed chamber. The controllable brake 500
preferably includes a controllable brake rotor 508 made integral
with the shaft, with the rotor 508 housed in the first sealed
chamber 504, with the rotor 508 having a rotation plane 570
preferably normal to the axis of rotation 516. The controllable
brake 500 preferably includes a controllable brake magnetic field
generator 510 located in the first chamber proximate the
controllable brake rotor 508, the controllable brake magnetic field
generator for generating a controllable magnetic field strength.
The controllable brake preferably includes a controllable brake
rotating magnetic target 518 made integral with the shaft proximate
the first shaft end 514 with the controllable brake rotating
magnetic target 518 housed in the second sealed chamber, and a
controllable brake electronics circuit board 520 mounted in the
second sealed chamber. Preferably the brake operation electronics
control board 520 controls and/or monitors the operation of the
controllable brake 500. The controllable brake electronics circuit
board 520 having a control board plane 522, the control board plane
522 oriented normal to the axis of rotation 516, a first electronic
noncontacting magnetic sensor 524 having a first sensor plane 526,
the first electronic noncontacting magnetic sensor 524 integrated
on the controllable brake electronics circuit board 520 with the
first sensor plane 526 parallel with the control board plane 522,
and a second electronic noncontacting magnetic sensor 528 having a
second sensor plane 530, the second electronic noncontacting
magnetic sensor 528 integrated on the controllable brake
electronics circuit board 520 with the second sensor plane 530
parallel with the control board plane 522 with the control board
plane 522 between the first sensor plane 526 and the second sensor
plane 530, the first electronic noncontacting magnetic sensor 524
and the second electronic noncontacting magnetic sensor 528
monitoring the rotation of the controllable brake rotating magnetic
target 518 and outputting a rotational position of the controllable
brake rotating magnetic target wherein the controllable magnetic
field strength generated by the controllable brake magnetic field
generator 510 is determined by the rotational position to control a
relative motion of the controllable brake rotor 508. The
controllable brake preferably includes a field responsive
controllable material 532 sealed in the first chamber 504,
preferably with the rheology of the field responsive controllable
material being affected by the magnetic field generator 510.
Preferably the electronic noncontacting magnetic sensors 524, 528
monitor the rotation of the rotating magnetic target 518,
preferably with the magnetic sensors 524, 528 oriented and mounted
relative to the shaft end 514 and its axis of rotation 516.
Preferably the electronic noncontacting magnetic sensors 524, 528
are substantially planar sensors, with their sensor plane normal to
axis of rotation 516, with the axis 516 centrally intersecting the
sensing centers of the sensors 524, 528 with the sensor's sensing
centers aligned with the axis 516. Preferably the magnetic target
518 is at the end of the shaft, preferably with the magnetic target
518 comprised of a magnet with north and south poles oriented
relative and normal to the shaft axis of rotation 516 with the
opposed N and S poles separated by the axis of rotation 516.
Preferably the field responsive controllable material 532 is
comprised of magnetic metal ferrous particles and lubricant,
preferably dry ferrous particles and dry lubricant (preferably dry
molybdenum disulfide). Preferably the controllable brake rotating
magnetic target 518 is a permanent magnet with a north pole (N) and
a south pole (S) opposed along a north south axis 534, with the
north south axis 534 perpendicular with the shaft axis of rotation
516. Preferably the controllable brake 500 includes field
responsive controllable material 532 sealed in the first chamber
504, with the field responsive controllable material 532 being
affected by the controllable magnetic field strength, and the
magnetic field generator 510 is adapted to generate a magnetic flux
in a direction through the field responsive controllable material
532 towards the rotor 508, and the controllable brake electronics
circuit board 520 provides a controlled current to the magnetic
field generator 510. Preferably the controllable brake 500 includes
a field responsive controllable material 532 sealed in the first
chamber 504 with a rheology of the field responsive controllable
material 532 being affected by the controllable magnetic field
strength, and the magnetic field generator 510 is adapted to
generate a magnetic flux 536 in a direction through the field
responsive controllable material 532 towards the rotor 508, and the
controllable brake electronics circuit board 520 provides a
controlled current 538 to the magnetic field generator 510.
Preferably the controllable brake shaft 512 is supported for
rotation about axis 516 by bearings 540 in the housing 502, and
further including seals 542 for sealing the first chamber to retain
the controllable material 532 therein, preferably with the first
and second chambers sealed from each other with the seals 542 and
the housing members to provide the first and second separate sealed
chambers 504,506, preferably with the field generator 510,
including a pole piece member 544 which provides for both the
generation of a magnetic field with an electromagnetic coil 546 and
a housing divider for separating the housing 502 into the first and
second chambers. Preferably the magnetic field generator 510
includes an electromagnetic coil 546 and the controllable brake
electronics circuit board 520 is electrically connected with the
magnetic field generator electromagnetic coil 546, preferably with
electrical contact connections leads 548 to the EM coil 546.
Preferably the electronics circuit board 520 provides a current 538
(i) to EM coil 546, for applying magnetic field flux 536 whose
strength is determined by the rotational position of the rotor 508,
with the magnetic target 518 rotation angle sensed by the sensors
524, 528. In a preferred embodiment at least one of the electronic
noncontacting magnetic sensors 524,528 include a magnetoresistive
material, preferably with electrical resistance changes in the
presence of the magnetic target 518 magnetic field, preferably with
magnetoresistive elements arranged in a Wheatstone bridge. In a
preferred embodiment at least one of the electronic noncontacting
magnetic sensors 524,528 includes a Hall Effect element, preferably
a plurality of oriented Hall Effect elements, preferably silicon
semiconductor Hall effect elements.
[0051] In a preferred embodiment the electronic noncontacting
magnetic sensor includes a magnetoresistive material, preferably
with electrical resistance changes in presence of a sensed magnetic
field, preferably with magnetoresistive elements arranged in a
Wheatstone bridge integrated circuit sensor chip with a planar
format providing a sensor plane. In a preferred embodiment the
electronic noncontacting magnetic sensor includes a Hall Effect
element, preferably a plurality of oriented Hall Effect elements,
preferably silicon semiconductor Hall effect elements arranged in
an integrated circuit sensor chip with a planar format providing a
sensor plane.
[0052] In an embodiment the invention includes a controllable
brake. The controllable brake preferably includes a rotating
magnetic target. The controllable brake preferably includes a
magnetically permeable rotor. The controllable brake preferably
includes a shaft connected to the magnetically permeable rotor. The
controllable brake preferably includes a housing having a first
housing chamber rotatably housing the magnetically permeable rotor
therein, and including a magnetic field generator spaced from the
magnetically permeable rotor, and configured and positioned for
generating a controllable magnetic field to control a relative
motion of the magnetically permeable rotor, and a second housing
chamber containing control electronics therein, the second housing
chamber electronics including at least a first oriented electronic
noncontacting magnetic sensor, the at least first oriented
electronic noncontacting magnetic sensor oriented relative to the
rotating magnetic target and the shaft wherein the at least first
oriented electronic noncontacting magnetic sensor monitors the
rotation of the rotating magnetic target.
[0053] Preferably the controllable brake 500 includes rotating
magnetic target 518. The controllable brake 500 preferably includes
magnetically permeable rotor 508. The controllable brake preferably
includes shaft 512 connected to the magnetically permeable rotor
508. The controllable brake preferably includes housing 502 having
a first housing chamber 504 rotatably housing the magnetically
permeable rotor 508 therein, and including a magnetic field
generator 510 spaced from the magnetically permeable rotor 508, and
configured and positioned for generating a controllable magnetic
field 536 to control a relative motion of the magnetically
permeable rotor 508, and a second housing chamber 506 containing
control electronics 520 therein, the second housing chamber
electronics 520 including at least a first oriented electronic
noncontacting magnetic sensor 524, the at least first oriented
electronic noncontacting magnetic sensor oriented relative to the
rotating magnetic target 518 and the shaft 512 wherein the at least
first oriented electronic noncontacting magnetic sensor monitors
the rotation of the rotating magnetic target 518. Preferably the
brake includes a controllable material 532, preferably contained in
the first chamber 504 between and preferably filling the space
between the magnetically permeable rotor 508 and the magnetic field
generator 510 with the magnetic field generator spaced from the
magnetically permeable rotor with the controllable material
in-between the two with the two configured and positioned for
generating a controllable magnetic field 536 to control the
relative motion of the magnetically permeable rotor 508 relative to
the magnetic field generator 510 with the magnetic field flux 536
through the controllable material 532 sealed in the first chamber
between the magnetically permeable rotor and magnetic field
generator controlling the relative motion. Preferably the at least
first electronic noncontacting magnetic sensor provides a detected
measured rotational position of the rotor, and the circuit board
520 control electronics are electrically connected with the
magnetic field generator 510 and provide electrical control of the
magnetic field generator 510 to apply a magnetic field 536 whose
strength is determined by the detected measured rotational position
of the rotor. Preferably the circuit board 520 control electronics
electrical contact connections leads 548 deliver a current 538 to
the EM coil 546, preferably with the electronics circuit board
providing current i to EM coil 546 for applying magnetic field 536
whose strength is determined by the relative rotational position of
the rotor 508 as the magnetic target rotation angle sensed by the
at least one noncontact oriented senor. Preferably the at least
first oriented electronic noncontacting magnetic sensor is
integrated into brake operation electronics control board 520
mounted in the second sealed chamber 506 wherein the brake
operation electronics control board 520 controls the operation of
the controllable brake 500. Preferably the noncontacting magnetic
sensor has a sensor plane 526, 530 oriented with the shaft axis of
rotation 516, preferably with the sensor plane parallel with
control board plane 522 with such normal to shaft axis of rotation
516, with the rotation axis 516 intersecting the sensor plane
proximate the sensing center of the noncontacting magnetic sensor.
Preferably the controllable brake 500 includes a second oriented
electronic noncontacting magnetic sensor 528, wherein the first
electronic noncontacting magnetic sensor 524 and the second
electronic noncontacting magnetic sensor 528 are integrated into
brake operation electronics control board 520 mounted in the second
sealed chamber 506 wherein the brake operation electronics control
board 520 controls and/or monitors the operation of the
controllable brake 500. Preferably the at least first and second
magnetic sensors 524, 528 have a sensor planes oriented with the
shaft axis of rotation 516, preferably with the sensor planes
parallel with control board plane 522, with such planes normal to
shaft axis of rotation, with the control board plane 522 between
the first and second sensor planes 526 and 530. Preferably the
brake operation electronics control circuit board 520 has a less
than one millimeter thickness between the first oriented electronic
noncontacting magnetic sensor 524 and the second oriented
electronic noncontacting magnetic sensor 528, and the rotating
magnetic target 518 is comprised a shaft oriented permanent magnet,
preferably with permanent magnet N-S pole axis 534. Preferably the
magnetic sensors have sensor planes oriented with the shaft axis of
rotation 516, preferably with the sensor planes parallel with the
control board plane, with such normal to the shaft axis of
rotation, with the control board plane of the less than one
millimeter thickness circuit board between the first and second
sensor planes.
[0054] In an embodiment the invention includes a method of
controlling motion. The method preferably includes providing a
housing having a first housing chamber and a second housing
chamber. The method preferably includes providing a shaft with a
magnetically permeable rotor, the shaft including a rotating
magnetic target distal from the magnetically permeable rotor. The
method preferably includes providing a magnetic field generator for
generating a magnetic field with a controllable field strength for
controlling a relative motion of the magnetically permeable rotor.
The method preferably includes providing at least a first
electronic noncontacting magnetic sensor, the at least first
electronic noncontacting magnetic sensor integrated on an operation
electronic control board having a control board plane. The method
preferably includes disposing the magnetically permeable rotor and
the magnetic field generator in the first housing chamber. The
method preferably includes disposing the rotating magnetic target
and the at least a first electronic noncontacting magnetic sensor
in the second housing chamber, wherein the operation electronic
control board is in electrical communication with the magnetic
field generator and the control board plane is oriented relative to
the rotating magnetic target, wherein the at least first electronic
noncontacting magnetic sensor provides a detected measured
rotational position of the rotating magnetic target with the
controllable field strength generated in relationship to the
detected measured rotational position sensed by the at least first
electronic noncontacting magnetic sensor.
[0055] Preferably the controlling motion method includes providing
a housing 502 having a first housing chamber 504 and a second
housing chamber 506. Preferably the controlling motion method
includes providing a shaft 512 with a magnetically permeable rotor
508, with the shaft including a rotating magnetic target 518 distal
from the magnetically permeable rotor 508. Preferably the
controlling motion method includes providing a magnetic field
generator 510 for generating a magnetic field with a controllable
field strength for controlling a relative motion of the
magnetically permeable rotor. Preferably the controlling motion
method includes providing a field responsive controllable material,
with the field responsive controllable material affected by the
magnetic field generator magnetic field. Preferably the provided
field responsive controllable material has a rheology which is
controllable by the generated magnetic field, preferably with a
field responsive controllable material 532 provided from magnetic
metal ferrous particles and lubricant, preferably dry ferrous
particles and dry lubricant (preferably dry molybdenum disulfide
lubricant). Preferably the controlling motion method includes
providing at least a first electronic noncontacting magnetic sensor
524, 528. Preferably the at least first electronic noncontacting
magnetic sensor is integrated on an operation electronic control
board 520 having a control board plane 522. Preferably the
controlling motion method includes disposing the magnetically
permeable rotor, the magnetic field generator, in the first housing
chamber. Preferably disposing the magnetically permeable rotor, the
magnetic field generator, in the first housing chamber includes
sealing such therein along with the field responsive controllable
material 532. Preferably the controlling motion method includes
disposing the rotating magnetic target 518 and the at least a first
electronic noncontacting magnetic sensor in the second housing
chamber 506, wherein the operation electronic control board 520 is
in electrical communication with the magnetic field generator 510
and the control board plane 522 is oriented relative to the
rotating magnetic target 518, wherein the at least first electronic
noncontacting magnetic sensor provides a detected measured
rotational position of the rotating magnetic target with the
controllable field strength generated in relationship to the
detected measured rotational position sensed by the at least first
electronic noncontacting magnetic sensor. Preferably the at least
first electronic noncontacting magnetic sensor has the sensor plane
(526, 530) oriented with the control board plane 522. Preferably
the sensor plane (526,530) is parallel with control board plane
522, with such normal to shaft axis of rotation 516, with rotation
axis 516 intersecting the sensor plane proximate the sensing center
of the sensor. Preferably the method includes providing a second
electronic noncontacting magnetic sensor with a sensor plane (526,
530) with the second electronic noncontacting magnetic sensor
integrated on the operation electronic control board with the
second electronic noncontacting magnetic sensor plane oriented
parallel with the control board plane, with the control board plane
between the second electronic noncontacting magnetic sensor plane
and the first electronic noncontacting magnetic sensor plane. In an
embodiment preferably at least one of the electronic noncontacting
magnetic sensor includes a magnetoresistive material, preferably
with electrical resistance changes in presence of the target
magnetic field, preferably with magnetoresistive elements arranged
in a Wheatstone bridge. In an embodiment preferably at least one of
the electronic noncontacting magnetic sensor includes a Hall Effect
element, preferably a plurality of oriented Hall Effect elements,
preferably silicon semiconductor Hall effect elements for sensing
shaft rotational changes of the target magnetic field.
[0056] In an embodiment the invention includes a method of making a
motion control brake for controlling motion. The method preferably
includes providing a magnetic field generator for generating a
magnetic field with a controllable field strength for controlling a
relative motion of a movable brake member. The method preferably
includes providing a magnetic target which moves with the relative
motion of the movable brake member. The method preferably includes
providing an electronic circuit board having a circuit board plane,
a first oriented electronic noncontacting magnetic sensor having a
first oriented sensor plane, the first electronic noncontacting
magnetic sensor integrated on the electronic circuit board with the
first sensor plane parallel with the circuit board plane, a second
oriented electronic noncontacting magnetic sensor having a second
oriented sensor plane, the second electronic noncontacting magnetic
sensor integrated on the electronic circuit board with the second
sensor plane parallel with the circuit board plane with the circuit
board plane between the second sensor plane and the first sensor
plane. The method preferably includes disposing the electronic
circuit board proximate the magnetic target wherein the first
electronic noncontacting magnetic sensor and the second electronic
noncontacting magnetic sensor provide a detected measured magnetic
target position with the controllable field strength generated by
the magnetic field generator determined by the detected measured
magnetic target position.
[0057] Preferably the method of making a motion control brake 500
includes providing a magnetic field generator 510 for generating a
magnetic field 536 with a controllable field strength for
controlling a relative motion of a movable brake member 508. The
method preferably includes providing a magnetic target 518 which
moves with the relative motion of the movable brake member 508. The
method preferably includes providing an electronic circuit board
520 having a circuit board plane 522, a first oriented electronic
noncontacting magnetic sensor 524 having a first oriented sensor
plane 526, the first electronic noncontacting magnetic sensor 524
integrated on the electronic circuit board 520 with the first
sensor plane 526 parallel with the circuit board plane 522, a
second oriented electronic noncontacting magnetic sensor 528 having
a second oriented sensor plane 530, the second electronic
noncontacting magnetic sensor 528 integrated on the electronic
circuit board 520 with the second sensor plane 530 parallel with
the circuit board plane 522 with the circuit board plane 522
between the second sensor plane 530 and the first sensor plane 526.
The method preferably includes disposing the electronic circuit
board 520 proximate the magnetic target 518 wherein the first
electronic noncontacting magnetic sensor 524 and the second
electronic noncontacting magnetic sensor 528 provide a detected
measured magnetic target position with the controllable field
strength generated by the magnetic field generator 510 determined
by the detected measured magnetic target position. Preferably the
movable brake member is comprised of a movable brake rotor 508,
preferably with a shaft 512 having a distal end permanent magnet
magnetic target 518 which moves with the relative motion of the
movable brake rotor. Preferably the electronic circuit board first
integrated oriented electronic noncontacting magnetic sensor 524
and its first oriented sensor plane parallel with the circuit board
plane and the second integrated oriented electronic noncontacting
magnetic sensor 528 with its second oriented sensor plane parallel
with the circuit board plane with the circuit board plane between
the second sensor plane and the first sensor plane, with the method
including the integrating and orienting the two sensors
overlappingly on both planar sides of the circuit board 520.
Preferably the overlapping integrated and oriented sensors and in
between circuit board are disposed proximate the magnetic target
518 wherein the first electronic noncontacting magnetic sensor 524
and the second electronic noncontacting magnetic sensor 528 provide
a detected measured magnetic target position with the controllable
field strength generated by the magnetic field generator 510
determined by the detected measured magnetic target position. The
method preferably includes providing a shaft 512 with the movable
brake member comprising rotor 508 and the magnetic target 518
includes a permanent magnet with a north pole and a south pole
opposed along a north south axis 534, preferably with the north
south axis 534 perpendicular with the shaft axis of rotation 516,
preferably with the movable brake member rotor 508 made integral
with the shaft 512 and the magnetic target permanent magnet 518
made integral with the shaft. Preferably the integrating the shaft
and rotor includes connecting the rotor with the shaft in a manner
to restrain relative rotation there between. Preferably the shaft,
the movable brake member rotor, and the magnetic target permanent
magnet have an axis of rotation 516 with the circuit board plane
522 oriented normal to the axis of rotation 516 with the axis of
rotation going through the sensor centers, preferably with the
north south axis 534 perpendicular with the shaft axis of rotation
516. Preferably the electronic circuit board 520 has a less than
one millimeter thickness between the first oriented electronic
noncontacting magnetic sensor 524 and the second oriented
electronic noncontacting magnetic sensor 528, and preferably the
rotating magnetic target 518 is comprised of a shaft oriented
permanent magnet. Preferably the first electronic noncontacting
magnetic sensor 524 and the second electronic noncontacting
magnetic sensor 528 provide the circuit board with at least a first
position output, at least a second position output, and at least a
third position output, and most preferably four simultaneously
detected position outputs, with the motion control brake
method/system including a position output processor for processing
the multiply position outputs, preferably with the position output
processor comparing the multiply outputs to determine if there is a
suspected error output and exclude such suspected error output from
the determination of the magnetic field generated to actively
control motion with the brake. Preferably the controllable brake
provides a multiply redundancy controllable brake sensor system
with the brake sensors at least three simultaneously sensed
positions outputs monitored and compared for suspected error
output, with error outputs excluded from the electronic control
system determination of controlling the applied magnetic field to
control the relative motion allowed by the brake, either within an
inner control loop operating within the brake or an outer control
loop within which the brake is integrated to provide the brake's
control of motion and outputted target sensed positions. In an
embodiment the electronic noncontacting magnetic sensors include
magnetoresistive materials with electrical resistance changes in
the presence of the magnetic target magnetic field, preferably with
sensor magnetoresistive elements arranged in a Wheatstone bridge to
sense the rotating magnetic field of the magnetic targets pole axis
534. In an embodiment the electronic noncontacting magnetic sensors
include a Hall Effect element, preferably a plurality of oriented
Hall Effect elements, preferably silicon semiconductor Hall effect
elements integrated together to sense the rotating magnetic field
of the magnetic targets pole axis 534.
[0058] In an embodiment the invention includes a method of making a
control system. The method preferably includes providing a control
system rotating magnetic target having an axis of rotation. The
method preferably includes providing a control system electronic
circuit board having a circuit board plane and a first circuit
board side and an opposite second circuit board side, a first
oriented electronic noncontacting magnetic sensor integrated on the
electronic circuit board first circuit board side, a second
oriented electronic noncontacting magnetic sensor integrated on the
electronic circuit board second circuit board side. The method
preferably includes disposing the control system electronic circuit
board proximate the control system rotating magnetic target with a
projected extension of the axis of rotation extending through the
first oriented electronic noncontacting magnetic sensor and the
second oriented electronic noncontacting magnetic sensor wherein
the first electronic noncontacting magnetic sensor and the second
electronic noncontacting magnetic sensor provide a plurality of
detected measured magnetic target rotary position outputs.
[0059] Preferably the method of making a control system includes
providing a control system rotating magnetic target 518 having an
axis of rotation 516. The method preferably includes providing a
control system electronic circuit board 520 having a circuit board
plane 522 and a first circuit board side 521' and an opposite
second circuit board side 521'', a first oriented electronic
noncontacting magnetic sensor 524 integrated on the electronic
circuit board first circuit board side 521', a second oriented
electronic noncontacting magnetic sensor 528 integrated on the
electronic circuit board second circuit board side 521''. The
method preferably includes disposing the control system electronic
circuit board 520 proximate the control system rotating magnetic
target 518 with a projected extension of the axis of rotation 516
extending through the first oriented electronic noncontacting
magnetic sensor 524 and the second oriented electronic
noncontacting magnetic sensor 528 wherein the first electronic
noncontacting magnetic sensor 524 and the second electronic
noncontacting magnetic sensor 528 provide a plurality of detected
measured magnetic target rotary position outputs. Preferably the
method includes integrating and orienting the two sensors
overlappingly on both planar sides of the circuit board 520.
Preferably overlapping, integrating and orienting the sensors on
the circuit board such that the circuit board is mountable
proximate the magnetic target 518 wherein the first electronic
noncontacting magnetic sensor 524 and the second electronic
noncontacting magnetic sensor 528 provide a plurality of
simultaneously detected measured magnetic target position outputs.
Preferably the magnetic target 518 includes a permanent magnet with
a north pole and a south pole opposed along a north south axis 534
with the north south axis perpendicular with the axis of rotation
516, preferably with the overlapping, integrated oriented sensors
524, 528, preferably providing at least a first position output, at
least a second position output, and at least a third position
output, and most preferably four simultaneously detected position
outputs, with the motion control system including a position output
processor for processing the multiply position outputs, preferably
with the position output processor comparing the multiply outputs
to determine if there is a suspected error output and exclude such
suspected error output from the control system process loop.
Preferably the control system provides a multiply redundancy
control sensor system with the sensors at least three
simultaneously sensed positions outputs monitored and compared for
suspected error output, with error outputs excluded from the
electronic control system determination control loops (either
within an inner control loop operating within the control system
electronic circuit board 520 or an outer control loop within which
the board is integrated into to provide the outputted target sensed
positions). In an embodiment the electronic noncontacting magnetic
sensors include magnetoresistive materials with electrical
resistance changes in the presence of the magnetic target magnetic
field, preferably with sensor magnetoresistive elements arranged in
a Wheatstone bridge to sense the rotating magnetic field of the
magnetic targets pole axis 534. In an embodiment the electronic
noncontacting magnetic sensors include a Hall Effect element,
preferably a plurality of oriented Hall Effect elements, preferably
silicon semiconductor Hall effect elements integrated together to
sense the rotating magnetic field of the magnetic targets pole axis
534. Preferably the electronic circuit board 520 has a less than
one millimeter thickness between the first oriented electronic
noncontacting magnetic sensor and the second oriented electronic
noncontacting magnetic sensor, and preferably the rotating magnetic
target includes a shaft oriented permanent magnet.
[0060] Preferably the first electronic noncontacting magnetic
sensor and the second electronic noncontacting magnetic sensor
provide the circuit board 520 with at least a first position
output, at least a second position output, and at least a third
position output, and preferably four simultaneously detected
position outputs, with the motion control system including a
position output processor for processing the multiply position
outputs, which preferably compares the multiply outputs to
determine if there is a suspected error output and exclude such
suspected error output from the determination in a control system
control loop step.
[0061] In an embodiment the invention includes a method of
controlling motion. The method preferably includes providing a
magnetic field generator for generating a magnetic field with a
controllable field strength. The method preferably includes
providing a field responsive controllable material, the field
responsive controllable material affected by the magnetic field
generator magnetic field. The method preferably includes providing
a magnetic target. The method preferably includes providing at
least a first electronic noncontacting magnetic sensor, the at
least first electronic noncontacting magnetic sensor integrated on
an operation electronic control board having a control board plane,
the operation electronic control board in electrical communication
with the magnetic field generator and the control board plane
oriented relative to the magnetic target, wherein the at least a
first electronic noncontacting magnetic sensor provides a detected
measured position of the magnetic target with the controllable
field strength generated in relationship to the detected measured
position sensed by the at least first electronic noncontacting
magnetic sensor.
[0062] Preferably the method of controlling motion includes
providing a magnetic field generator 510 for generating a magnetic
field 536 with a controllable field strength. The method preferably
includes providing a field responsive controllable material 532,
the field responsive controllable material affected by the magnetic
field generator magnetic field. The method preferably includes
providing a magnetic target 518. The method preferably includes
providing at least a first electronic noncontacting magnetic sensor
524, the at least first electronic noncontacting magnetic sensor
524 integrated on an operation electronic control board 520 having
a control board plane 522, the operation electronic control board
520 in electrical communication with the magnetic field generator
510 and the control board plane 522 oriented relative to the
magnetic target 518, wherein the at least a first electronic
noncontacting magnetic sensor 524 provides a detected measured
position of the magnetic target 518 with the controllable field
strength 536 generated in relationship to the detected measured
position sensed by the at least first electronic noncontacting
magnetic sensor 524. Preferably providing a field responsive
controllable material 532 includes providing a material rheology
which is field responsive, with the field responsive controllable
material rheology affected and controllable by the magnetic field
generator magnetic field 536, preferably the provided field
responsive controllable material 532 is comprised of magnetic metal
ferrous particles and lubricant, preferably dry ferrous particles
and dry lubricant (preferably dry molybdenum disulfide). Preferably
the provided magnetic target is a rotating magnetic target, that
preferably provides a rotating magnetic field with the permanent
magnet pole axis 534. Preferably the at least first electronic
noncontacting magnetic sensors provide a detected measured
rotational position of the magnetic target with the controllable
magnetic field strength generated in relationship to the detected
measured rotational position sensed by the at least first
electronic noncontacting magnetic sensor. Preferably the at least
first electronic noncontacting magnetic sensor 524 has a sensor
plane 526 oriented with the control board plane 522. Preferably the
at least first electronic noncontacting magnetic sensor plane 526
is oriented normal with the shaft axis of rotation 516. Preferably
the sensor plane 526 is parallel with control board plane 522, with
such normal to shaft axis of rotation 516, with the axis 516
intersecting sensor plane proximate the sensing center of the
sensor 524. Preferably the method includes providing second
electronic noncontacting magnetic sensor 528 with a sensor plane
530, with the second electronic noncontacting magnetic sensor 528
integrated on the operation electronic control board 520 with the
second electronic noncontacting magnetic sensor plane 530 oriented
parallel with the control board plane 522, with the control board
plane 522 between the second electronic noncontacting magnetic
sensor plane 530 and the first electronic noncontacting magnetic
sensor plane 526. In an embodiment the electronic noncontacting
magnetic sensors include magnetoresistive materials with electrical
resistance changes in the presence of the magnetic target magnetic
field, preferably with sensor magnetoresistive elements arranged in
a Wheatstone bridge to sense the rotating magnetic field of the
magnetic targets pole axis 534. In an embodiment the electronic
noncontacting magnetic sensors include a Hall Effect element,
preferably a plurality of oriented Hall Effect elements, preferably
silicon semiconductor Hall effect elements integrated together to
sense the rotating magnetic field of the magnetic targets pole axis
534.
[0063] Preferably the circuit board 520 includes electrical
environmental protection circuitry. Preferably the circuit board
circuitry includes electrical environmental protection circuitry
560 such as shown in FIG. 3. Preferably the circuit board circuitry
includes a voltage regulator which drops down a first supplied
voltage to the board down to a lowered sensor voltage for the
sensor, such as the LM2931 voltage regulator such as shown in FIG.
3 dropping down the 12 volt power down to the 5 volt power supplied
to the sensors 524, 528. Preferably the electrical environmental
protection circuitry includes an electromagnetic filter providing
EMC filtering protection. Preferably the circuit board 520 includes
a first and a second power source, with the circuit board
controlling the supply, conditioning and distribution of electrical
power from the at least two power sources, to provide a controlled
current 538 to the brake coil 546. The circuit board 520 provides
control, supply, conditioning and distribution of current to the
sensors 524, 528 and the EM coil 546 of the field generator 510,
and output sensed angular position data such as shown in FIG. 4.
Additionally in an embodiment the control system includes an outer
control loop with the EM coil controlled outside the inner loop
utilizing the output sensed angular position data from the sensors
and board control system, such as with the FIG. 4 output data used
to determine and produce a control current to EM coil 546 to
control a relative motion with the brake 500. Preferably the at
least two power sources provide for power supply to the same
sensor. In a preferred embodiment the first power supply provides
power to both sensors, with a backup secondary power supplied to
the sensors from the second power supply. In preferred embodiments
the 12 volt power to the circuit board 520 and the outputted sensed
angular position data from the sensors are provided through the
electronics outer loop conduit utilizing two separate cables
routing the wiring into the second chamber 506. Preferably two
separate cabled power supplies are supplied to the double sided
board 520, with the circuit board 520 providing two isolated power
supplies to a sensor. Preferably two separate cabled power supplies
are supplied to the double sided board 520, with the circuit board
520 including electronics to send power to the EM brake coil 546,
preferably at least with a control current 538 provided such as
with the current control flyback diode steer current from two
isolated power supplies supplied to the brake EM coil 546. In a
preferred embodiment the board includes a processor that determines
on board with an inner loop in the brake 500 to provide the control
current 538 to the EM coil 546 based on the sensed position of the
magnetic target 518, preferably with a position output processor
processing the multiply position outputs from the sensors, which
preferably compares the multiply outputs to determine if there is a
suspected error output and exclude such suspected error output from
the determination in the system control loop step. Preferably one
set of electrical contact connections 548 deliver the control
current 538 to the EM coil from the diode steering array. As shown
in FIG. 4, the integrated oriented first and second sensors provide
four detected target positions, preferably providing the absolute
angular position of the rotating magnetic target 518, the shaft
512, and the rotor 508, preferably with the four outputs monitored
and compared to detect a suspected erroneous output which in turn
is ignored and not utilized in the determination of controlling the
motion of the rotor with the field generator 510. FIG. 4 shows the
positional outputs from two integrated circuit semiconductor sensor
chip electronic noncontacting magnetic sensors 524, 528 mounted to
opposing sides of a circuit board 520 for detecting the rotation of
the target 518, the shaft 512, and the rotor 508. Channels 1 and 2
(Ch1, Ch2) show the at least two positional outputs (Ch1, Ch2) for
the first integrated circuit semiconductor sensor chip electronic
noncontacting magnetic sensor. Channels 3 and 4 (Ch3, Ch4) show the
at least two positional outputs (Ch3, Ch4) for the second
integrated circuit semiconductor sensor chip electronic
noncontacting magnetic sensor. In this embodiment each of the
integrated circuit semiconductor sensor chip electronic
noncontacting magnetic sensors provided simultaneously two
positional outputs (Ch1, Ch2) and (Ch3, Ch4). Preferably the
electronic noncontacting magnetic sensor integrated circuit
semiconductor sensor chip has at least two dies. Preferably the at
least two dies are ASICs (Application Specific Integrated
Circuits). In a preferred embodiment the at least two dies are side
by side dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the at least two dies are vertically
stacked dies in the integrated circuit semiconductor sensor chip.
In a preferred embodiment the integrated circuit semiconductor
sensor chip ASIC die include a magnetoresistive material,
preferably with electrical resistance changes relative to the
rotating shaft magnetic target magnetic field, preferably with
magnetoresistive elements arranged in a Wheatstone bridge. In a
preferred embodiment the integrated circuit semiconductor sensor
chip ASIC die include a Hall Effect element, preferably a plurality
of oriented Hall Effect elements, preferably silicon semiconductor
Hall effect elements which detect changes relative to the rotating
magnetic target magnetic field of the rotating shaft magnetic
target.
[0064] It will be apparent to those skilled in the art that various
modifications and variations can be made to the invention without
departing from the spirit and scope of the invention. Thus, it is
intended that the invention cover the modifications and variations
of this invention provided they come within the scope of the
appended claims and their equivalents. It is intended that the
scope of differing terms or phrases in the claims may be fulfilled
by the same or different structure(s) or step(s).
* * * * *